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Author Topic: gearbox removal process 1.8tdci  (Read 808 times)

Offline paul1966

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  • Model: C-Max
  • Spec: 1.8 tdci
  • First Name: Paul
  • Region: East Midlands
gearbox removal process 1.8tdci
« on: May 04, 2018, 02:40:07 PM »
tomorrow i am removing the gearbox on my 1.8tdci c-max, reading the haynes manual you seem to have to remove a lot of stuff before you remove the box, i have read on here the process for removing a box from a S-max which seemed quite straight forward, can anyone thats already done this before confirm roughly what needs removing in order to fully remove the gearbox from the car?

Offline mike wilson

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Re: gearbox removal process 1.8tdci
« Reply #1 on: May 08, 2018, 01:18:03 PM »
Can't go into detail as it was so long ago but it is certainly one heavy piece of kit.  Must be close to 200lbs and awkward with it.  Be careful.

Offline paul1966

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Re: gearbox removal process 1.8tdci
« Reply #2 on: May 08, 2018, 03:46:07 PM »
thanks, we did the job on Saturday, all went to plan except that the reason for changing the box was knotchy stiff gears, i asked ford to check the cables before i did any major work and they said the cables were fine and it was the synchro on the box, the new box feels identical when changing gear so ford must have got it wrong about the cables, it must have been a quick check they did as there was no charge!. next step it to try to adjust the cables, can't see what else it could be now.

Offline johnnyroper

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Re: gearbox removal process 1.8tdci
« Reply #3 on: May 08, 2018, 04:02:57 PM »
Certainly worth trying to adjust the cables as they can go out of adjustment and cause selection issues.

Offline mike wilson

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Re: gearbox removal process 1.8tdci
« Reply #4 on: May 09, 2018, 09:53:27 AM »
Not a slightly draggy clutch?  It needs to be very slight to affect gear change but show no other signs.  Did you change fluid/bleed it?

Offline paul1966

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  • Spec: 1.8 tdci
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  • Region: East Midlands
Re: gearbox removal process 1.8tdci
« Reply #5 on: May 09, 2018, 02:57:30 PM »
we fitted a new flywheel, clutch & slave cylinder and made sure there is no air in the new slave cylinder, so pretty much everything has been changed and it feels exactly the same, knotchy when changing gear. its just got to be the cables surely?

Offline mike wilson

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Re: gearbox removal process 1.8tdci
« Reply #6 on: May 10, 2018, 09:53:01 AM »
Certainly sounds like it.  I have a vague memory of someone having an issue with corrosion on the gearlever pivot.  I'm not confusing it with the known problem with VW based Galaxys, etc.  But I may have misremembered.

Offline Chrispb

  • Mindsaysyesbodysaysnono
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Re: gearbox removal process 1.8tdci
« Reply #7 on: May 10, 2018, 11:17:42 AM »
Is the selection the same without the engine running or is it easier smoother.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline paul1966

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  • Posts: 10
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  • Model: C-Max
  • Spec: 1.8 tdci
  • First Name: Paul
  • Region: East Midlands
Re: gearbox removal process 1.8tdci
« Reply #8 on: May 10, 2018, 12:43:23 PM »
its exactly the same with engine on or off and foot on clutch or off. i disconnected the cables at the box and the gear stick moved freely so i don't think there is anything wrong with the stick mechanism, although with the gear stick console fitted its hard to see. i plan to adjust the cables at the box end this weekend.

Offline Chrispb

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Re: gearbox removal process 1.8tdci
« Reply #9 on: May 10, 2018, 02:34:41 PM »
Before you try any cable adjustment have you tried moving the gearbox levers by hand to engage gears, you should be able to select gears fairly easily.
If the levers are tight or stiff then you may have that problem where corrosion/oxidation partly seizes the shafts in the aluminium casing.
May benefit from a good dose of penetrating oil.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline paul1966

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  • Model: C-Max
  • Spec: 1.8 tdci
  • First Name: Paul
  • Region: East Midlands
Re: gearbox removal process 1.8tdci
« Reply #10 on: May 10, 2018, 02:46:47 PM »
yep tried that when i had the cables off and it went into gear ok, just had a look at the box i took out and it seems that the cable with the adjuster on controls the vertical up down motion of the gear selector. the haynes manual says it should be set to something like 25mm, playing around with the height does make the gear hard to get in so hopefully it that that needs adjusting, all gears feel the same which kinds of makes sense as if the height is wrong it will effect all gears. here's hoping.

Offline johnnyroper

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Re: gearbox removal process 1.8tdci
« Reply #11 on: May 10, 2018, 05:58:59 PM »
Certainly sounds like cable adjustment had similar on my Alfa recently with difficult selection worse when warm. 2 issues found with mine the pin on vertical selector on box was seizing so stick not self centering. Also cables had stretched so when I pinned box selector and stick I had to adjust both cables in order to get them back on. Basically it causes the gate to not completely line up inside box so it baulks when selecting.

Not sure how it’s done on your car but older fords used to come with a plastic lock for the gear lever to hold it central you then popped cables off box  so selector on that was in central position. And adjusted cables to suit. I seem to remember there being a ratchet type adjuster on the cable that adjusted it??

Offline paul1966

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  • Model: C-Max
  • Spec: 1.8 tdci
  • First Name: Paul
  • Region: East Midlands
Re: gearbox removal process 1.8tdci
« Reply #12 on: May 10, 2018, 06:45:38 PM »
well tonight i have been looking at the box we took off to see what i needed to do, going by the haynes book, unfortunately the picture in the book does not relate to what i have on my box which is not very helpful. but i think all they are doing is setting the height of the gear changer to put it in 4th gear then you adjust the cable, what i plan to do is engage 4th gear then get someone to hold the gearstick in position and undo the cable on the box and hopefully see that it needs slight adjustment. i'm off to do some googling to see if there is any better info about.

 

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